Icing Machine and Icing Method

ABSTRACT

A system for the automated coating of baked good with a water based icing is provided. In particular, a system for the automated movement of icing and controls of variables such as temperature, moisture, and/or flow rate of the icing is provided to maintain the characteristics of the icing for extended periods of operation of an associated coating system.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation of International Application No.PCT/US2015/065221, filed Dec. 11, 2015, which claims the benefit of U.S.provisional Patent Application No. 62/092,020, filed Dec. 15, 2014,which are incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

The present invention relates to the automated coating of bakery with anicing such as a water based icing. In particular, the present inventionrelates to the automated movement of icing which controls variables suchas temperature, moisture, and/or flow rate of the icing alone or incombination to maintain the characteristics of the icing for extendedperiods of operation of an associated coating system.

SUMMARY OF THE INVENTION

One embodiment relates to an icing coating system. The icing coatingsystem includes a temperature regulated return hopper, a belt, a beltsprocket assembly, a belt support arrangement, a variable speed drive, apan, a variable-flow rate icing pump, a structure and a catch basin. Thetemperature regulated icing return hopper includes walls defining areservoir for containing an icing and a heat exchanger in thermalcommunication with the reservoir wall. The belt conveys a food productto be coated with icing, the belt includes openings through which icingcan flow. The belt sprocket assembly and the belt support arrangementmoveably support the belt such that a top portion of the belt movesbetween the belt sprocket and the belt support in a direction and abottom portion of the belt moves between the belt sprocket and the beltsupport in a direction opposite to the top portion, the top portion ofthe belt including a top surface and a bottom surface. The variablespeed drive is coupled to the belt sprocket arrangement to move the beltat a selectable speed. The pan is located between the top portion of thebelt and the bottom portion of the belt. The variable-flow rate icingpump is in fluid communication between the reservoir and the pan to pumpicing from the reservoir to the pan. The structure supports the beltsprocket assembly and the belt support arrangement and the icing pansuch that the pan is located between the top and bottom portions of thebelt and the bottom surface of the top portion of the belt is furthersupported by the pan through the openings of the belt and above the topsurface of a belt such that at least a portion of food items located onthe belt are resting within and coated with icing. The catch basin belowthe structure for receiving excessing icing from the pan.

Another embodiment relates to a coating system usable for coating bakerysuch as donuts and cookies. The system includes a temperature regulatedicing return hopper, a belt, a belt sprocket assembly, a belt supportarrangement, a variable speed drive, a pan, a variable-flow rate icingpump, a structure and a water induction system. The temperatureregulated icing return hopper includes walls defining a reservoir forcontaining the icing and a heat exchanger in thermal communication withthe reservoir walls, wherein the hopper includes a fluid jacket throughwhich fluid at a predetermined temperature flows to regulate thetemperature of the icing to reduce evaporation of moisture from theicing. The belt conveys bakery to be coated with icing, the beltincludes openings through which icing can flow. The belt sprocketassembly and the belt support arrangement moveably support the belt suchthat a top portion of the belt moves between the belt sprocket and thebelt support in a direction and a bottom portion of the belt movesbetween the belt sprocket and the belt support in a direction oppositeto the top portion, the top portion of the belt includes a top surfaceand a bottom surface. The variable speed drive is coupled to the beltsprocket arrangement to move the belt at a selectable speed. The pan islocated between the top portion of the belt and the bottom portion ofthe belt. The variable-flow rate icing pump is in fluid communicationbetween a catch basin and the pan to pump icing from the reservoir tothe pan. The structure supports the belt sprocket assembly and the beltsupport arrangement and the icing pan such that the icing pan is locatedbetween the top and bottom portions of the belt and the bottom surfaceof the top portion of the belt is further supported by the pan. Thewater induction system controls the moisture content of the icing. Thewater induction system includes a moisture sensor for sensing the watercontent of icing in the system, a controllable water injector for addingwater to icing in the system, and a controller coupled to the moisturesensor and the water injector to cause water to be added to maintainicing within the moisture content required to maintain selectedproperties of icing flowing within the system, wherein the flow rate ofthe icing pump is controlled to force icing into the pan through theopenings of the belt and above the top surface of a belt such that atleast a portion of the surfaces of bakery located on the belt areresting within and coated with icing.

Another embodiment relates to a method of preparing bakery such asdonuts and cookies. The method includes the steps of containing icing ina temperature controlled vessel, sensing the temperature and moisture oficing contained within the vessel, heating the vessel and adding waterto the icing to maintain the temperature and moisture of the icingwithin a predetermined range, continuously moving icing from the vesselthrough a belt to the top surface of the belt which supports the bakeryand moving the belt while the bakery is in contact with the belt andicing for a predetermined distance.

Another embodiment relates to a combination. The combination includes adonut, a vessel, a belt, a pump and a support structure. The vesselincludes temperature and moisture controlled water-based icing. The beltincludes a top surface which supports the donut. The pump is for pumpingicing from the vessel through the belt onto the surface of the donut.The support structure for moveably supporting the belt relative to thevessel such that excess icing flows from the belt back into the vessel.

Another embodiment relates to a machine for simultaneously coating aplurality of items with a coating. Each item has a first side and asecond side. The items are placed on the machine in rows which aresubstantially straight and substantially perpendicular to the directionof travel of the items through the machine. The machine includes a firstbelt including openings through which the coating can flow. The machinealso includes a first conveyor having a first end and a second end. Thefirst conveyor moveably supports the first belt such that a top portionof the belt moves in a coating direction. The top portion transitions toa bottom portion of the belt at the second end, the top portionsupporting and conveying a plurality of rows of a plurality of the itemsbetween the first and second ends in the coating direction. The itemsare supported on the first sides. The machine further includes a firstvariable speed drive coupled to the first conveyor to move the topportion in the coating direction. The machine also includes a panlocated between the top and bottom portions of the first belt. Themachine additionally includes a variable-flow rate icing pump configuredto pump the coating into the pan and through the openings to coat thefirst side of the items with the coating as the items move above thepan. The machine includes a second belt and a second conveyor whichmoveably supports the second belt such that a top portion of the secondbelt moves in the coating direction. The machine includes a secondvariable speed drive coupled to the second conveyor to move the topportion of the second belt in the coating direction and a sensor whichgenerates a signal in response to the passing of the plurality of rowsof the plurality of items. The machine has a structure which supportsthe second conveyor relative to the first conveyor such that coateditems drop from the first belt onto the top portion of the second belt.The items drop such that the items are resting upon the second sidesafter being dropped onto the second belt, the structure furthersupporting the senor relative to the top portion of the first beltproximate to the second end. The machine additionally includes acontroller coupled to the variable speed drives and the sensor. Thecontroller controls the first variable speed drive to move the topportion of the first belt at an average speed, and controls the secondvariable speed drive to vary the speed of the second belt in response tothe signal generated by the sensor. The variable speed of the secondbelt is such that the second belt moves at a drop speed which is belowthe average speed of the first belt when the items are dropped onto thesecond belt.

Another embodiment relates to a method for coating a plurality of itemswith a coating, each item having a first side and a second side. Themethod including the step of placing the items on a first belt includingopenings through which the coating can flow. The method includes thestep of moveably supporting the first belt such that a top portion ofthe belt moves in a first direction. The top portion transitions to abottom portion of the belt at an end. The bottom portion moves in asecond direction opposite to the first direction, the top portionsupporting and conveying a plurality of rows of a plurality of the itemsbetween the first and second ends in the first direction wherein thecooked items are supported on the first sides. The method furtherincludes the step of controllably moving the top portion in the firstdirection at an average speed. The method also includes the step ofpumping the coating into a pan located between the top and bottomportions of the first belt and through the openings to coat the firstside of the items with the coating as the items move above the pan. Themethod further includes the step of moveably supporting a second beltsuch that a top portion of the second belt moves in the first direction.The direction of the top portion of the second belt is such that theitems are dropped from the second end of the first belt onto the topportion of the second belt. The method also includes sensing theplurality of rows of the plurality of items passing along the first beltat the end. The method further includes varying the speed of the secondbelt when the plurality of rows of the plurality of items are sensed.Varying the speed of the second belt is such that the second belt movesat a drop speed which is below the average speed of the top portion ofthe first belt when the items are dropped onto the second belt.

Another embodiment relates to a coating system for coating items with aliquid coating such as glaze, icing or frosting. The system includes areturn hopper defining a reservoir for containing a coating. The systemfurther includes a belt for conveying a food product to be coated withthe coating. The belt includes openings through which the coating canflow. The system also includes a belt sprocket assembly and a beltsupport arrangement for moveably supporting the belt. The belt issupported such that a top portion of the belt moves between the beltsprocket and the belt support in a direction and a bottom portion of thebelt moves between the belt sprocket and the belt support in a directionopposite to the top portion. The top portion of the belt includes a topsurface and a bottom surface. The system also includes a variable speeddrive coupled to the belt sprocket arrangement. The variable speed driveis used to move the belt at a selectable speed. The system additionallyincludes a pan located between the top portion of the belt and thebottom portion of the belt. The system further includes a first pump influid communication between the reservoir and the pan. The first pump isused to move the coating from the reservoir to the pan at a firstcontrollable flow rate. The system further includes a catch basin belowthe belt for receiving excess coating from the pan. The system furtherincludes a proportional valve. The proportional valve has an input port,a first output port in fluid communication with the pan and a secondoutput port in fluid communication with the return hopper. Theproportional valve is controllable to vary a ratio of the relative flowof the coating from the first and second output ports. The systemfurther includes a second pump in fluid communication between the catchbasin and the input port of the proportional valve. The second pump isused to move the coating from the catch basin to the input port at asecond controllable flow rate. The second pump generates a firstthickness signal representative of the thickness of the coating. Thesystem further includes a structure which supports the belt sprocketassembly and the belt support arrangement and the pan. The supportstructure is configured such that the pan is located between the top andbottom portions of the belt and a bottom surface of the top portion ofthe belt is further supported by the pan. The controllable flow rates ofthe first and second pumps and the ratio are controlled to selectivelymove the coating from the return hopper and the catch basin into the panbased at least upon the thickness signal.

Another embodiment relates to a method for coating cooked items with acoating such as glaze, icing or frosting. The method includes the stepsof moving cooked items on a belt over a pan. The belt includes openingsthrough which the coating flows to a level above the belt and intocontact with the items. The method further includes moving the coatingfrom a return hopper to the pan at a first flow rate. The method furtherincludes moving the coating from a catch basin to the pan at a secondflow rate and to the return hopper at a third flow rate. The catch basinis located below the pan to catch excess coating. The method furtherincludes controlling the first, second and third flow rates based uponthe thickness of the coating from the catch basin.

Alternative exemplary embodiments relate to other features andcombinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingfigures, wherein like reference numerals refer to like elements inwhich:

FIG. 1A is a side view of a pastry decorating line system according toan exemplary embodiment, which includes an organizing system, aninjection system, an icing coating system, a topping system, and adrizzling system.

FIG. 1B is a top view of the pastry decorating line system of FIG. 1A.

FIG. 2 is a perspective view of an icing coating system according to anexemplary embodiment.

FIG. 3 is a side view of a hopper of the ice coating system according toan exemplary embodiment.

FIG. 4 is a cross-section view of the hopper of the ice coating systemaccording to an exemplary embodiment.

FIG. 5A is a perspective view of a conveyor belt of the ice coatingsystem according to an exemplary embodiment.

FIG. 5B is a top view of the conveyor belt of the icing coating systemof FIG. 5A according to an exemplary embodiment.

FIG. 5C is a sectional view of the conveyor belt of the icing coatingsystem along line C-C of FIG. 5B according to an exemplary embodiment.

FIG. 5D is a perspective view of a tracker shaft of the ice coatingsystem labeled as 5D in FIG. 5C according to an exemplary embodiment.

FIG. 6 is a diagram of a control system for the icing coating systemaccording to an exemplary embodiment.

FIG. 7 is a flow-diagram showing a method for icing a pastry withwater-based icing according to an exemplary embodiment.

FIG. 8A is a sectional view of another embodiment of the conveyor beltof the icing coating system.

FIG. 8B is a close up view of a portion of the icing conveyor of theicing coating system of FIG. 8A.

FIG. 9 is a schematic view of an alternative embodiment of the flow pathfor icing in the system.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of an automatedicing coating system for icing food products with icings such aswater-based icing are shown. Typically, the food products discussedherein include pastries such as donuts, cookies, bagels, cakes, rolls,etc. The pastries may be toroidal in shape. The icing coating system isan automated process for icing pastries with an icing such as awater-based icing for an extended period of operation while maintainingthe characteristics of the icing by controlling variables such as icingtemperature, moisture level of the icing, speed of the conveyor belt,and/or icing flow rate. Generally, the system disclosed herein includesa continuous conveyor belt for moving the pastries through the systemcontrolled by a variable speed drive, a temperature regulated icingreturn hopper, a variable flow rate icing pump, and a structure tosupport the system. Furthermore, the configuration of the systemdisclosed herein reduces the amount the icing is pumped for a givennumber of bakery pieces coated. In operation, the icing coating systemcan be one of many systems in a pastry decorating line system.

Referring to FIGS. 1A and 1B, a pastry decorating line system 20 isshown according to an exemplary embodiment. FIG. 1A shows a side view ofpastry decorating line system 20 while FIG. 1B shows the top view ofpastry decorating line system 20. Pastry decorating line system 20includes an organizing system 24, an injection system 26, an icingcoating system 28, a topping system 30 and a drizzling system 32. Afirst operator 22 feeds pastries 23 into the pasty decorating linesystem 20 at input point 21. Pastries 23 move down pastry decoratingline system 20 by way of a series of conveyor belts in the directionshown by arrow 25. In the embodiment shown in FIG. 1A and FIG. 1B,pastries 23 are first lined up into rows by organizing system 24 on aconveyor 10. The conveyor 10 is a series of belts that extend from theorganizing system 24 to the drizzling system 32. In one embodimentwithin coating system 28, the conveyor 10 includes conveyor belts 10 a,10 b, and 10 c. Conveyor belts 10 a and 10 b are fabricated fromstainless steel wire to form a belt mesh 104 which defines a pluralityof openings 102. Conveyor belt 10 c may be fabricated from a stainlesssteel mesh belt or a polyurethane belt which may be scraped with ascraper 47 a and/or 47 b (see FIG. 5C and FIG. 8A) to remove icing frombelt 10 c during operation. In another embodiment, within coating system28, conveyor 10 includes a single continuous conveyor belt. The conveyor10 transports pastries 23 from organizing system 24 to injection system26. At injection system 26, pastries 23 are injected with a filling.Conveyor 10 continues to transport pastries 23 from injection system 26to icing coating system 28. A portion of pastries 23 are coated with alayer of icing 68 at icing coating system 28. In one embodiment, icing68 may be chocolate flavored. In other embodiments, icing 68 may beother flavors such as vanilla, maple, strawberry, etc. Pastries 23 withicing 68 continue to be transported on conveyor 10 from ice coatingsystem 28 to topping system 30. Topping system 30 dispenses a topping,such as sprinkles, powder sugar, etc., onto pastries 23 with icing 68.Pastries 23 with icing 68 and topping continue to be transported fromtopping system 30 to drizzling system 32. Pastries 23 are drizzled witha second icing at drizzling system 32. The systems that make up pastrydecorating line system 20 can be removed and/or interchanged to producethe desired pastry. For example, pastry decorating line system 20 maynot include injection system 26 or topping system 30, but may stillinclude icing coating system 28 and drizzling system 32. Once thepastries 23 are through pastry decorating line system 20, a secondoperator 34 removes pastries 23 from pastry decorating line system 20from output point 35. In one embodiment, pastries 23 are complete atoutput point 35. In another embodiment, pastries 23 are then directed toa packaging system where they are packaged for sale and/or storage.

Referring to FIG. 2, an embodiment of icing coating system 28 is shownthat includes conveyor belts 10 a, 10 b and 10 c, an icing return hopper12 and a support structure 64. Icing 68 is transported between returnhopper 12 and conveyor belt 10 b. Icing coating system 28 also includesa controller 202 (shown in FIG. 6) and a temperature sensor 204 (shownin FIG. 6) that are associated with monitoring the temperature, moisturecontent and flow rate of icing 68. In one embodiment, controller 202 andtemperature sensor 204 maintain the temperature of icing 68 in icingcoating system 28 between 115° F. and 135° F., specifically between 120°F. and 130° F. and more specifically, the temperature of icing 68 may beapproximately 125° F. In another embodiment, the target temperature maybe at about 105° F. because some types of icing and frostings are tooviscous for coating purposes below 105° F. and break down too fast above105° F. Accordingly, it would be advantageous to maintain the icingideally near 105° F. or at least within the range of 100° F. to 110° F.Return hopper 12 includes a gear reduction drive 14, a motor 15, a shaft16, a reservoir 17, a heat exchanger 208 (shown in FIG. 6), conduit 62and a paddle 11 (shown in FIG. 4). Return hopper 12 is temperatureregulated which includes walls defining reservoir 17. Gear reductiondrive 14 and motor 15 operate together to control the movement of shaft16. Shaft 16 extends from outside reservoir 17 into the interior ofreservoir 17. During operation of icing coating system 28, icing 68 ispumped through conduit 62 from return hopper 12 to an icing pan 70 by avariable-flow rate icing pump 78. Icing 68 enters icing pan 70 through apump outlet 80. Another portion of conduit 62 extends from a catch basin7, located underneath a portion of conveyor belt 10 b, to return hopper12. A second variable-flow rate icing pump 79 pumps icing 68 from catchbasin 7 back to return hopper 12. Portions of conduit 62 may havetemperature regulated water flowing in an insulated jacket 112 tomaintain proper flow rate of icing 68 throughout icing coating system28. Insulated jacket 112 extends around the entire circumference ofconduit 62 and includes water flowing between insulated jacket 112 andthe exterior surface of conduit 62. Support structure 64 houses aportion of icing coating system 28 and supports various parts of icingcoating system 28 discussed below. In one embodiment, support structure64 is on wheels to make icing coating system 28 more portable.

Referring to FIG. 3, reservoir 17 is a temperature regulated double wallstructure that includes an outer wall structure 76 and an inner wallstructure 18 (shown in FIG. 4) that contains icing 68. Heat exchanger208 is in thermal communication with outer wall structure 76 and innerwall structure 18 of reservoir 17. Outer wall structure 76 includes acylindrical wall 81, an angled wall 83, a bottom end 84 and a top end86. Top end 86 receives a portion of conduit 62 and is generallycircular in shape and includes a door 88 and a first opening (not shownin figures). Door 88 provides a user access to cavity 9 (shown in FIG.4) of reservoir 17 by lifting a handle 90. Door 88 is coupled to top end86 by a hinge, fastener, etc., allowing door 88 to move about the hinge.Top end 86 is adjacent to cylindrical wall 81. Cylindrical wall 81extends between top end 86 and angled wall 83. Angled wall 83 extendsfrom cylindrical wall 81 towards bottom end 84. Angled wall 83 isgenerally frustoconical in shape and includes diameters with varyinglengths. For example, the diameter of angled wall 83 near thecylindrical wall 81 is greater than the diameter of angled wall 83 nearbottom end 84. Bottom end 84 is adjacent to angled wall 83 and isgenerally circular in shape. Bottom end 84 includes a second openingthat receives a portion of conduit 62. In other embodiments reservoir 17may have different configurations and shapes in order to operate with avariety of systems. For example, reservoir 17 may be more rectangular inshape, with the bottom end and top end being more rectangular in shapeas well. Additionally, it is preferable to provide an insulation fillinggap (e.g., filled with foam insulation) between inner wall structure 18and outer wall structure 76.

Referring to FIG. 4, the inner wall structure 18 includes an innercylindrical wall 74 and an inner angled wall 72 that defines a cavity 9that contains icing 68 in return hopper 12. Outer wall structure 76 ofreservoir 17 is in thermal communication with a heat exchanger 208,which heats a fluid jacket 82. Fluid jacket 82 is located in the spacebetween inner wall structure 18 and outer wall structure 76. Fluidjacket 82 includes a fluid flowing at a predefined temperature, such aswater, to regulate the temperature of icing 68 to reduce evaporation ofmoisture from icing 68 in return hopper 12. In other embodiments, returnhopper 12 may be resistively heated and the fluid flowing in fluidjacket 82 may be in the form of steam or mist. The temperature controlfor temperature regulated icing 68 in return hopper 12 is describedbelow.

Referring to FIG. 4, the paddle 11 extends from the shaft 16 in cavity 9of reservoir 17. Water is introduced into the reservoir 17 in the formof mist, steam or both via shaft 16 or a separate spray or mist nozzle.In the exemplary embodiment, paddle 11 rotates around a central axis 89at the same rate as shaft 16 and is used to continuously move or agitateicing 68 located in cavity 9 of reservoir 17. In other embodiments,paddle 11 may move up and down repeatedly in a vertical direction inorder to continuously move icing 68 located in cavity 9 of reservoir 17or paddle 11 may move both in a vertical direction, while simultaneouslyrotating around central axis 89. In addition to paddle 11, an assemblyof plastic scrapers may be attached to shaft 16 to rotate with thepaddle and scrape the interior of the reservoir during operation.

Referring to FIGS. 5A-5C, an exemplary embodiment of icing coatingsystem 28 is shown. FIG. 5A shows a perspective view of icing coatingsystem 28. FIG. 5B shows a top view of icing coating system 28. FIG. 5Cshows a sectional view of icing coating system 28 along line C of FIG.5B.

Referring to FIGS. 5A-5C, support structure 64 supports a belt sprocketassembly, a belt support arrangement and icing pan 70. Conveyor belts 10a-c of icing coating system 28 are continuous belts for conveying foodproduct, such as pastries, donuts, cookies, etc., to be coated withicing 68. Conveyor belts 10 a-c are engaged with and movably supportedby belt sprocket assembly that includes a plurality of sprockets 36 andbelt support arrangement that includes a plurality of cylinders 38. Theplurality of cylinders 38 are connected by bearings to support structure64 and are supported by support structure 64. Cylinders 38 aresubstantially perpendicular to the direction of travel of conveyor belts10 a-c of icing coating system 28. The belt sprocket assembly and beltsupport arrangement are configured such that top portions 52 of conveyorbelts 10 a-c move between cylinders 38 in a first direction 40 andbottom portions 54 of conveyor belts 10 a-c moves between cylinders 38in a second direction 42 opposite to first direction 40 of top portions52. The top portions 52 have top surfaces 94 and bottom surfaces 96. Inother embodiments, conveyor belts 10 a-c may be able to changedirections during or in between operation(s) of icing coating system 28.

In the embodiment shown in FIGS. 5A-5C, a plurality of pastries 23 isshown entering icing coating system 28 at input end 44 and exit at anoutput end 92 transporting pastries 23 to topping system 30 (shown inFIG. 1A and FIG. 1B). Icing coating system 28 includes an in-feedconveyor 58 including conveyor belt 10 a, icing conveyor 60 includingconveyor belt 10 b, and out-feed conveyor 61 including conveyor belt 10c. Pastries 23 first enter at in-feed conveyor 58, continue to betransported to icing conveyor 60, and then are transported to out-feedconveyor 61. In-feed conveyor 58 is angled such that the input end 44 islower than the end near the icing conveyor 60. In-feed conveyor 58 islocated before icing conveyor 60 in a configuration that allows pastries23 to be rotated/flipped 180° as they transition from in-feed conveyor58 onto icing conveyor 60 of icing coating system 28 in the directionshown by arrow 66. In other embodiments such as shown in FIG. 8A,in-feed conveyor 58 is not angled, such that pastries 23 enter icingcoating system 28 at input end 44 from in-feed conveyor 58 at the samerelative level as icing conveyor 60 and pastries 23 are not rotated 180°as they enter icing conveyor 60. In other embodiments, an operator canload the pastries 23 directly onto in-feed conveyor 58 at the input end44 of icing coating system 28.

Referring to FIGS. 5A-5C, icing conveyor 60 receives pastries 23 fromin-feed conveyor 58. The top portion 52 of icing conveyor 60 is locatedbelow the end of in-feed conveyor 58 near icing conveyor 60 such thatthere is a vertical distance between the top portion 52 of in-feedconveyor 58 and top portion 52 of icing conveyor 60. Top portion 52 oficing conveyor 60 includes a substantially horizontal section 98 and anangled section 100. The angled section 100 extends downwards from thehorizontal section 98 towards out-feed conveyor 61. Icing conveyor 60includes icing pan 70 located in between top portion 52 and bottomportion 54 of conveyor belt 10 b. More specifically, the bottom surface96 of top portion 52 of conveyor belt 10 b is further supported by icingpan 70. Variable-rate icing pump 78 continuously pumps icing 68 fromreturn hopper 12 into icing pan 70 via a distribution tube 71 having aplurality of openings located in the tube to cause icing 68 to flow fromdistribution tube 71 in direction 41 opposite to direction 40. By way ofexample, the openings in distribution tube 71 may be circular holesspaced along the tube and exiting the tube in direction 41 where thespacing of the openings is selected depending upon the icing type andfrosting flow required for a particular coating operation. The ratio ofthe volume of icing pan 70 to the volume of distribution tube 71 isbetween 0.045 and 0.055 and in one embodiment is exactly 0.05. In analternative embodiment depicted in FIG. 8A and FIG. 8B the ratio of thevolume of icing pan 70 to the volume of distribution tube 71 is higher,ranging from 0.9 to 1.1 and in another embodiment is exactly 1.0. Ahigher volume ratio between the icing pan 70 and the distribution tube71 allows more of the icing 68 to remain in the tube 71 resulting inless evaporation. The flow rate of variable-rate icing pump 78 iscontrolled to force icing 68 into icing pan 70 through openings 102 ofconveyor belt 10 b and above top surface 94 of conveyor belt 10 b suchthat at least a portion of pastries 23 on top surface 94 of conveyorbelt 10 b are resting within and are then coated with icing 68. Bycausing the icing to flow in direction 41, the icing level is higherabove conveyor belt 10 b in the direction 41 than in direction 40 whichimproves the coating of the pastries 23 by providing a higher icinglevel when the pastry first comes into contact with the coating(direction 41 is omitted in FIG. 8A do to size constraints, see FIG. 8Bfor a close up view). The horizontal section 98 receives pastries 23from in-feed conveyor 58. Pastries 23 are transported on icing conveyor60 towards out-feed conveyor 61. A portion of pastries 23 are coatedwith a layer of icing 68 when pastries 23 pass through the layer oficing 68 formed above the top surface 94. Pastries 23 continue to betransported from horizontal section 98 towards angled section 100 withthe iced side facing down towards top surface 94. In other embodiments,a roller assembly system is located above layer of icing 68 to ensurethat pastries 23 are held down into layer of icing 68, therebypreventing pastries 23 to float on top of layer of icing 68 and failingto maintain a depth sufficient to coat a portion of pastries 23 withicing 68.

Referring to FIGS. 5A -5C, pastries 23 are transported down angledsection 100 towards out-feed conveyor 61. Angled section 100 is angledsuch that pastries 23 rotate approximately 180° from icing conveyor 60onto out-feed conveyor 61. In other embodiments, such as depicted inFIG. 8A, icing conveyor 60 does not contain an angled section 100. Insuch embodiments, the distance between icing conveyor 60 and out-feedconveyor 61 is such that pastries 23 will rotate approximately 180° whentransitioning from icing conveyor 60 onto out-feed conveyor 61. Topportion 52 of icing conveyor 60 is located above top portion 52 ofout-feed conveyor 61 such that there is a vertical distance between thetop portion 52 of icing conveyor 60 and out-feed conveyor 61. Thevertical distance between the in-feed conveyor 58 and icing conveyor 60is greater than the vertical distance between the icing conveyor 60 andthe out-feed conveyor 61. Out-feed conveyor 61 angles upwards such thatthe end near icing conveyor 60 is lower than output end 46. Out-feedconveyor 61 then moves pastries 23 coated with icing towards output end46 of icing coating system 28. Pastries 23 with icing 68 are thencomplete or ready to be moved to the next system in pastry decoratingline system 20, e.g., topping system 30. In other embodiments, thevertical distances may be the same between the in-feed conveyor 58 andicing conveyor 60 and icing conveyor 60 and out-feed conveyor 61. Inother embodiments, the vertical distance between in-feed conveyor 58 andicing conveyor 60 may be smaller than the vertical distance betweenicing conveyor 60 and out-feed conveyor 61.

Referring to FIGS. 5A-5C, in operation, by continuously pumping icing 68into icing pan 70, icing 68 passes through the openings 102 of the beltmesh 104, such that icing 68 forms a layer above the belt mesh 104 aboveicing pan 70. Any excess icing 68 that does not adhere to pastries 23spills over from icing pan 70 to catch basin 7. Icing 68 that spillsover to catch basin 7 is pumped back to return hopper 12 by secondvariable-flow rate icing pump 79 (shown in FIG. 2) through a portion ofconduit 62. Variable-flow rate icing pump 78 is in fluid communicationbetween icing pan 70 and reservoir 17 to pump icing 68 from reservoir 17to icing pan 70. Second variable-flow rate pump 79 is in fluidcommunication between catch basin 7 and reservoir 17 to pump execs icing68 from catch basin 7 to reservoir 17. In another embodiment, icing pan70 is located under both top portion 52 and bottom portion 54 of icingconveyor 60. Top portion 52 and bottom portion 54 of icing conveyor 60are configured close together so that icing 68 from icing pan 70 mayflow up through both portions of icing conveyor 60 and create a layer oficing 68 on top portion 52 of icing conveyor 60 above belt mesh 104.

Referring to FIGS. 5A-5C, the thickness of icing 68 located aboveopenings 102 is controlled by pump flow rate and the speeds of conveyorbelts 10 a-c of in-feed conveyor 58, icing conveyor 60 and out-feedconveyor 61. Conveyor belts 10 a-c of in-feed conveyor 58, icingconveyor 60 and out-feed conveyor 61 are controlled by a variable speeddrive that is coupled to the belt sprocket arrangement to move conveyorbelts 10 a-c of in-feed conveyor 58, icing conveyor 60 and out-feedconveyor 61 at a selectable speed. The flow rate of variable-flow rateicing pump 78 may also be adjusted to reach the desirable thickness forthe layer of icing 68. The variable-flow rate icing pump 78 is in fluidcommunication between reservoir 17 and icing pan 70 to pump icing 68from reservoir 17 to icing pan 70. The speed control for in-feedconveyor 58, icing conveyor 60 and out-feed conveyor 61 and the flowrate control for variable-flow rate icing pump 78 are described below.

Referring to FIG. 5D, icing conveyor 60 includes a tracker shaft 48.Tracker shaft 48 includes a sleeve 50, a plurality of discs 56, a pairof drive sprockets 106 and a shaft 108. Tracker shaft 48 supports aportion of icing conveyor 60 and secured to support structure 64 with afastening device, e.g., bolts and nuts. Shaft 108 includes a first end114 and a second end 116. The distance between first end 114 and secondend 116 is greater than the width of icing conveyor 60. Shaft 108 iscylindrical in shape fabricated from various types of metal, e.g. steel.In other embodiments shaft 108 may be made of a thermoplastic materialand in various shapes and lengths. Sleeve 50 is annular in shape andencircles shaft 108. The length of sleeve 50 is less than the distancebetween first end 114 and second end 116 of shaft 108.

Referring to FIG. 5D, discs 56 are annular in shape with a substantiallysmooth surface and encompass a portion of sleeve 50. In the exemplaryembodiment, tracker shaft 48 has 7 discs 56 that are evenly spaced apartfrom each other on sleeve 50 between drive sprockets 106. For example,the distance between two neighboring discs 56 may be 10 inches and thedistance between another set of two neighboring discs 56 is also 10inches. In other embodiments, there may be more or less than 7 discs 56and discs 56 may be spaced apart from each other with varying distances.For example, the distance between a set of neighboring discs 56 may be10 inches and the distance between another set of neighboring discs 56may be less than or greater than 10 inches. Each disc 56 includes a pairof washers 118 with one washer 118 abutting each side of disc 56. Onewasher 118 faces towards first end 114 and the other washer 118 facestowards second end 116. Washers 118 are annular in shape and encompasssleeve 50. The diameter of washers 118 is less than the diameter ofdiscs 56. In one embodiment, discs 56 may rotate freely on shaft 108between washers 118 to improve the support of icing conveyor 60 so thatthe amount of icing 68 from pastries 23 with icing 68 (e.g., donuts)which may be pulled from pastry 23 when it passes over tracker shaft 48is reduced.

Referring to FIG. 5D, drive sprockets 106 are located near the ends oftracker shaft 48. One drive sprocket 106 is located near first end 114and the other drive sprocket is located near second end 116. Drivesprockets have a center opening that permit shaft 108 and sleeve 50 topass through drive sprocket 106. Drive sprockets 106 include a pluralityof teeth 120. Each tooth 120 includes an angled portion 122, a roundedportion 124 and a tip 126. Teeth 120 extend from the outer surface ofdrive sprocket 106 at an angle less than 90° towards tip 126. Tip 126 isthe area of tooth 120 that is located farthest from the outer surface ofdrive sprocket 106. Rounded portion 124 extends from tip 126 towards theouter surface of drive sprocket 106 forming a curve. Teeth 120 areformed to not remove a substantial portion of icing 68 on pastry 23 thatit may come in contact with on icing conveyor 60. In other embodiments,teeth 120 may not include a rounded portion 124 and include 2 angledportions 122 or teeth 120 may not include angled portion 122 and include2 rounded portions 124. Teeth 120 may also extend from the outer surfaceof drive sprocket 106 at an angle that is greater than 90°.

Referring to FIG. 6, icing coating system 28 may include one or morecontrol systems 200 configured to control the operation of icing coatingsystem 28 to provide for effective and/or efficient icing of pastries 23over an extended operation period. In one embodiment, control system 200is configured to control the temperature of icing 68 in icing coatingsystem 28, the moisture level of icing 68 in icing coating system 28,the speed of conveyor belts 10 a-c of in-feed conveyor 58, icingconveyor 60, and out-feed conveyor 61, and the flow rate ofvariable-flow rate icing pumps 78 and 79 in a fluid control system.Various embodiments of control system 200 may include all four of thesecontrols or a combination of one or more thereof

Referring to FIG. 6, a diagram of control system 200 configured tocontrol icing coating system 28 is shown according to an exemplaryembodiment. Control system 200 includes controller 202 coupled to one ormore sensors, shown as temperature sensor 204 and moisture sensor 206.Controller 202 is also configured to generate and send control signalsto a heat exchanger 208, a water intake valve 210, a variable speeddrive 212 coupled to conveyor belts 10 a-c, and variable-flow rate icingpumps 78 and 79. Heat exchanger 208 may be any device or combination ofdevices capable of heating the fluid (e.g., water) that flows throughfluid jacket 82 of return hopper 12 or the fluid that flows betweenconduit 62 and insulated jackets 112. Water intake valve and injector210 is a device that allows water to be introduced into icing 68 inreturn hopper 12. The water introduced into icing 68 in return hopper 12may be in the form of steam, mist or both. Variable speed drive 212 is adevice that determines how fast conveyor belts 10 a-c move. Thecomponents of control system 200 are communicably coupled together bycommunication links 216 configured to transmit signals throughoutcontrol system 200 to provide the various functionalities discussedherein.

To control the temperature of icing 68 in return hopper 12, temperaturesensor 204 monitors the temperature of either icing 68 inside returnhopper 12, fluid in fluid jacket 82 of return hopper 12, the surfacetemperature of inner structure 18 and outer structure 76 of returnhopper 12, or fluid between conduit 62 and insulated jackets 112. Invarious embodiments, temperature sensor 204 can be a variety ofdifferent temperature sensor types including, but not limited to, athermometer, an infrared sensor, or a thermocouple sensor. In oneembodiment, controller 202 adjusts the temperature of the fluid in fluidjacket 82 of return hopper 12 based on temperature information receivedfrom temperature sensor 204 to heat icing 68 in return hopper 12 to theproper temperature and/or maintain icing 68 in return hopper 12 at theproper temperature. In such embodiments, controller 202 receives asignal or data via communication link 216 from temperature sensor 204indicative of the temperature of icing 68 in return hopper 12. Ifcontroller 202 determines that the temperature of icing 68 is above athreshold, controller 202 sends a control signal to heat exchanger 208to reduce the temperature of the fluid in fluid jacket 82 of returnhopper 12 or the fluid flowing in between conduit 62 and insulatedjackets 112. If controller 202 determines that the temperature of icing68 is below a threshold, controller 202 sends a control signal to heatexchanger 208 to increase the temperature of the fluid in fluid jacket82 of return hopper 12 or the fluid in between the conduit 62 andinsulated jacket 112 until it reaches the proper temperature. In otherembodiments, heat exchanger 208 may increase the temperature of thefluid in both the fluid jacket 82 and fluid in between conduit 62 andinsulated jacket 112 simultaneously.

Referring to FIG. 6, the moisture content of icing 68 in icing coatingsystem 28 is controlled by a water induction system. The water inductionsystem includes a moisture sensor 206, water intake valve and injector210 and controller 202. Moisture sensor 206 senses the water content oficing 68 in icing coating system 28. Water intake valve and injector 210adds water to icing 68 in icing coating system. Controller 202 iscoupled to moisture sensor 206 and water intake valve and injector 210to cause water to be added to icing 68 to maintain icing 68 within apercentage range of the moisture content required to maintain selectedproperties of icing 68 flowing within icing coating system 28. Moisturecontent of icing 68 may be monitored within return hopper 12, at theintake to variable-flow rate icing pump 78, within conduit 62, or atanother point in icing coating system 28 depending upon the particularconfiguration and lengths of icing flow paths and icing area. In apreferred embodiment, controller 202 adjusts the moisture content oficing 68 by adding moisture in the form of water, mist, steam orcombination of moisture forms, when the moisture content drops below athreshold value. In such an embodiment, controller 202 receives a signalor data via communication link 216 from moisture sensor 206 indicativeof the moisture content of icing 68 in return hopper 12 or another areathroughout icing coating system 28. If controller 202 determines thatthe moisture content of icing 68 is below a threshold, controller 202sends a control signal to water intake valve and injector 210 to addmoisture in the form of water, mist, steam or combination of moistureforms, to icing 68 in return hopper 12. In a preferred embodiment, watermay be injected into icing 68 as icing 68 is pumped throughvariable-flow rate icing pump 78 to ensure mixing. In other embodiments,water may be injected into conduit 62 or return hopper 12. Bycontrolling the moisture content of icing 68, relatively constantmechanical flow and application properties of icing 68 can be maintainedduring application of icing 68 to pastries 23 over an extended period oftime.

Referring to FIG. 6, the speed of conveyor belts 10 a-c is controlled byeither an operator manually setting the desired speed for conveyor belts10 a-c at controller 202 or controller 202 is communicably connected bycommunication link 216 to variable speed drive 212, which is coupled toconveyor belts 10 a-c. Variable speed drive 212 controls a plurality ofspeed drives 110 located in icing coating system 28. Icing coatingsystem includes at least 3 speed drives 110 (shown in FIG. 5A). Onespeed drive 110 controls the speed of conveyor 10 a of in-feed conveyor58, another speed drive 110 controls the speed of conveyor 10 b of icingconveyor 60, and another speed drive 110 controls the speed of conveyor10 c of out-feed conveyor 61. In the exemplary embodiment, the desiredspeed for conveyor belts 10 a-c is between 6.2 FPM and 11.00 FPM,specifically between 6.7 FPM and 10.5 FPM and more specifically, between7.2 FPM and 10.0 FPM. Once an operator determines desired speed,controller 202 sends a control signal to variable speed drive 212comprising the desired speed of conveyor belts 10 a-c. Variable speeddrive 212 then moves conveyor belts 10 a-c at the desired speed. In analternative embodiment, the controller 202 is communicably connected tothe speed drives 110, and the variable speed drive 212 is omitted. Inthis embodiment, the controller 202 controls the speed of each speeddrive 110 such that the average speed of conveyor belts 10 a-c is thesame as when the variable speed drive is employed.

In another embodiment, icing coating system 28 includes a sensor and asecond variable speed drive. In this embodiment, the first variablespeed drive is connected to the speed drives 110 for the in-feedconveyor 58 and icing conveyor 60, and the second variable speed driveis connected to the speed drive 110 for out-feed conveyor 61. The sensoris supported by the support structure 64 and is located where thepastries 23 transition from icing conveyor 60 to out-feed conveyor 61.Pastries 23 move along conveyor belt 10 b in a plurality of rows, witheach row having a plurality of pastries aligned perpendicular to thedirection 40 of the top portion 52 of conveyor belt 10 b. The rows ofthe plurality pastries 23 enter icing conveyor 60 with the fronts andback of all the pastries 23 in each of the plurality of row alignedtogether. In some instances, the pastries may become miss-aligned in therow during the icing process, such that the fronts of some pastries arefurther along conveyor 10 b than other pastries in the same row.Additionally, as the pastries transition from icing conveyor 60 toout-feed conveyor 61, a strings of icing may break off from the pastries23 and be left dangling off the end of icing conveyor 60. The strings oficing may drop down on to conveyor 10 c or create an undesirable tailingeffect of the pastries 23 as they drip off the end of icing conveyor 60.

The sensor is electrically coupled to the controller 202 and configuredto sense or detect the front end of a pastry 23 that is the forward mostpastry 23 in the row passing along icing conveyor 60 just before ittransitions to out-feed conveyor 61 and sense or detect the rear of thebackmost pastry 23 in the same row. In one embodiment, the sensor is aphoto eye sensor. In response to detecting the forward most pastry 23,the sensor generates a first signal and sends that signal back to thecontroller 202. A second signal is generated in response to detectingthe rear of the backmost pastry 23 in the same row. In an alternativeembodiment the sensor only detects the front most pastry and the secondsignal is generated in response to a preprogramed time variable. Thepreprogramed time variable may be calculated based on a statisticalmodal of the likely position of the plurality of pastries 23 in a singlerow after passing through the icing 68. In this instance the secondsignal may be generated within the controller 202. The controller 202receives the first signal from the sensor and sends a control signal tothe second variable speed drive. The second variable speed drive adjuststhe speed of conveyor belt 10 c in response to the first signal.Likewise, the controller 202 receives the second signal from the sensorand sends a control signal to the second variable speed drive. Thesecond variable speed drive adjusts the speed of conveyor belt 10 c inresponse to the second signal. Changing the seed of conveyor belt 10 cin this manner allows for realignment of the pastries 23. The change inspeed also allows for the string of icing left on the end of icingconveyor 60 to drip down directly on top of the pastries 23, thusreducing or eliminating the undesirable tailing effect and the drippingof icing 68 directly on to conveyor 10 c. In one embodiment, conveyorbelt 10 c is stopped in response to the first signal and sped up inresponse to the second signal, such that the average speed of conveyorbelt 10 c is equal to the average speed of conveyor belt 10 b. Inanother embodiment, no variable speed drives are used and the controllerdirectly operates the speed drives 110 of the icing conveyor 60 andout-feed conveyor 61 to achieve the same results as above.

Referring to FIG. 6, the flow rate that controls fluid control systemincludes a temperature sensor 204, sensor pump 214, controllable heatsource and controller 202. Controller 202 is coupled to a sensor pump214 and heat source to control the flow of the sensor pump 214 and theheat source based upon a signal generated by temperature sensor 204representative of the temperature of icing 68 in the icing coatingsystem 28. The fluid control system may also be controlled by anoperator manually setting the desired flow rate of sensor pump 214 beingpumped from return hopper 12 to icing pan 70. In the exemplaryembodiment icing 68 is pumped at approximately 6.0 gallons per minute.In other embodiments, the flow rate of icing 68 may be more or less than6.0 gallons per minute. Controller 202 is communicably connected tosensor pump 214 by communication link 216. Once an operator determinesdesired flow rate, controller 202 sends a control signal to sensor pump214 indicating the amount of icing 68 to be pumped through conduit 62from return hopper 12 to icing pan 70.

Referring to FIG. 6, icing 68 layer depths are determined by the speedof conveyor belts 10 a-c and the flow rate of sensor pump 214. In oneembodiment, controller 202 has pre-set settings for variouspre-determined layer depths of icing 68. An operator may select thedesired layer depth of icing 68 and controller 202 will send controlsignals to conveyor belts 10 a-c and sensor pump 214 to meet therespective conveyor speed and pump flow rate that produces the desiredlayer depth of icing 68.

Referring to FIG. 7, a method 300 of preparing bakery such as donuts,cookies, pastries, etc. with icing 68 is shown according to an exemplaryembodiment. In one embodiment, method 300 is performed using icingcoating system 28 described above. At step 302, icing 68 is loaded intoand contained in reservoir 17. Reservoir 17 is a temperature controlledvessel. At step 304, the temperature and moisture level of icing 68 inreservoir 17 is continuously sensed and detected. At step 306, reservoir17 is heated and water is added in the form of mist, steam or both, toicing 68 to maintain the temperature and moisture level of icing 68within a predetermined range. At step 308, icing 68 is continuouslymoved from reservoir 17 to top surface 94 of conveyor belt 10 b throughopenings 102 in conveyor belt 10 b. Top surface 94 of conveyor belt 10 bsupports pastries 23 being conveyed through the layer of icing 68. Atstep 310, conveyor belt 10 b moves pastries 23 through layer of icing 68on top surface 94 of conveyor belt 10 b for a predetermined distance.Method 300 may also include further steps of conveying pastries 23without icing 68 to in-feed conveyor 58 and conveying pastries 23 withicing 68 away from out-feed conveyor 61. Method 300 may also include astep of forcing pastries 23 into icing 68 on top surface 94 of theconveyor belt 10 b by using a roller assembly system.

FIG. 9 is a schematic view of an alternative embodiment of the flow oficing in icing coating system 28. In this embodiment, icing 68 flowinginto icing pan 70 can be sourced from reservoir 17 and/or catch basin 7.In this embodiment, a proportional valve 128 is in fluid communicationwith second variable icing pump 79, icing pan 70, and reservoir 17 oficing return hopper 12. Proportional valve 128 has an input port 130, afirst output port 132, and a second output port 134. The second variableicing pump 79 is in fluid communication with catch basin 7 and inputport 130. Second output port 134 is in fluid communication withreservoir 17, and first output port 132 is in fluid communication withicing pan 70. Input port 130 is in fluid communication with first andsecond output ports 132 and 134. In one embodiment, second output port134 is coupled to the end of distribution tube 71 opposite pump outlet80. As in other embodiments described above, first variable icing pump78 is in fluid communication with reservoir 17 and icing pan 70.

In operation, first variable icing pump 78 pumps icing from reservoir 17through conduit 62 into icing pan 70 at pump outlet 80 throughdistribution tube 71. Icing 68 passes through the holes in distributiontube 71 into icing pan 70 and flows in direction 41 up through openings102 in conveyor belt 10 b, where a portion of icing 68 coats pastries23. Excess icing 68 that is not used to coat pastries 23 is collected incatch basin 7. Second variable icing pump 79 pumps icing 68 from catchbasin 7 to input port 130. Icing output from second output port 134 ispumped to reservoir 17 by second variable icing pump 79, and icingoutput from first output port 132 is pumped into icing pan 70 by secondvariable icing pump 79. In one embodiment, the total amount of icing 68output at first output port 132 and second output port 134 is equal tothe amount of icing received at input port 130.

The proportional valve 128 is controllable to vary the ratio of therelative flow rates of the icing 68 output from first output port 132and second output port 134. In this embodiment, the amount of icing 68output from first output port 132 ranges form 0-100% of the icing 68received at input port 130, as the ratio of the proportional valve 128is varied between 0 and 1. A ratio of 1 represents 100% of icing 68received at input port 130 being output from first output port 132 and aratio of 0 represents 0% of icing 68 received at input port 130 beingoutput from first output port 132. In an alternative embodiment,proportional valve 128 is flipped such that a ratio of 1 represents 0%of icing 68 received at input port 130 being output from first outputport 132 and a ratio of 0 represents 100% of icing 68 received at inputport 130 being output from first output port 132. In one embodiment, theamount of icing 68 output from second output port 134 equals the amountof icing received at input port 130 minus the amount of icing 68 outputfrom first output port 132. Other embodiments are contemplated where aportion of icing 68 received at input port 130 is diverted outside thesystem to be disposed of rather than pumped out from first output port132 or second output port 134.

During operation of icing coating system 28, the icing 68 is exposed tovarious stresses as it move through the pumps 78 and 79, flows fromreservoir 17 to catch basin 7. These stresses are the result ofmovement, shear, heat, and/or friction. Over time exposure to these andother stresses breaks down icing 68 to a point where it is no longersuitable for use in coating pastries 23. To more quickly used stressedicing and prevent waste, more of icing 68 may be recycled from catchbasin 7 into icing pan 70 as it begins to break down. As icing 68 beginsto break down, the thickness of icing 68 increases and it becomes moredifficult to pump icing 68 through the system.

Second variable icing pump 79 is configured to generate a firstthickness signal representative of the thickness of icing 68.Proportional valve 128 is then controlled to vary the ratio in responseto the first thickness signal. This process can be done manually orautomatically by use of a control system such as controller 202.Typically, the thickness signal would be based upon the amperagerequired to power the motor which powers pump 79. This amperage is arelatively reliable indicator of motor torque which is related to thethickness of the material being pumped by the associated pump i.e. pump79.

In automatic operation, the first thickness signal generated based uponthe torque applied to pump 79 is sent to controller 202. Controller 202controls the ratio of proportional valve 128 in response to the firstthickness signal. In one embodiment, controller 202 increases the ratioas the first thickness signal increases relative to previous values ofthe first thickness signal stored in the controller 202 and decreasesthe ratio as the first thickness signal decreases relative to previousvalues of the first thickness signal stored in the controller 202. Inthis way a greater percentage of icing 68 is recycled from catch basin 7into icing pan 70 as icing 68 thickens and begins to break down. Inanother embodiment controller 202 sets the ratio by comparing thereceived first thickness signal to a database of values stored incontroller 202 that indicate a specific ratio to set for a specificthickness signal or range of thickness signals. In another embodiment,first variable icing pump 78 generates a second thickness signal (basedupon the amperage required to power the motor powering pump 78) which issent to controller 202. Controller 202 compares the first thicknesssignal to the second thickness signal, and increases the ratio when thefirst thickens signal is greater than the second thickness signal.

In another embodiment, icing coating system 28 includes a coating levelsensor (not shown) attached to the catch basin 7. The coating levelsensor generates a level signal representative of the level of icing 68held within catch basin 7. In one embodiment the level signal is sent tocontroller 202. Controller 202 controls the flow rates A and C ofvariable icing pumps 78 and 79 respectively and the ratio in response tothe level signal. For example, if the level signal indicates the levelof icing 68 within catch basin 7 is low, controller 202 will increasethe amount of icing 68 flowing into icing pan 70 by increasing flow rateA to draw more icing 68 from reservoir 17 and/or increase the ratio torecirculate more icing 68 from catch basin 7 into icing pan 70.

In another embodiment, icing coating system 28 includes a coating signalgenerator (not shown), which generates a coating signal representativeof the desired coating level of pastries 23. The coating signalgenerator passes the coating signal to the controller 202, which willadjust the flow rate of first variable icing pump 78, the flow rate ofsecond variable icing pump 79, and/or the ratio of proportional valve128 as necessary to achieve the desired coating level.

In one embodiment, the time it takes for icing 68 to be drained firstfrom catch basin 7 or reservoir 17 is dependent on the various flowrates of icing within the system. As described above, the flow rates Aand C for first and second variable icing pumps 78 and 79 respectivelyare independently controllable either manually or by controller 202. Theflow rates B and D from first and second output ports 132 and 134respectively are dependent on the flow rate C of second variable icingpump 79 and the selected ratio of proportional valve 128. Flow rates Band D may be expressed in terms of flow rate C and the ratio ofproportional valve 128. Flow rate B equals the ratio times flow rate Cand flow rate D equals flow rate C time the result of 1 minus the ratio.In an alternative embodiment, the proportional valve 128 is flipped suchthat the Flow rate D equals the ratio times flow rate C and flow rate Bequals flow rate C time the result of 1 minus the ratio. The flow rate Eof icing 68 that coats pastries 23 is independent and may be varied bychanging the speed of conveyor belt 10 b. The time until reservoir 17 isdrained of icing 68 is determined by subtracting flow rate D from flowrate A and dividing the result by the volume of icing in reservoir 17.The time until catch basin 7 is drained is determined by adding togetherthe flow rates E and C, subtracting off flow rates A and B and dividingthe result by the volume of icing 68 in catch basin 7.

In one embodiment, where flow rate D is equal to flow rate C times 1minus the ratio, five options are contemplated for varying theindependent flow rates A, C, and E to vary whether icing 68 is drainedfrom reservoir 17 or catch basin 7. First, icing 68 will drain fromreservoir 17 and hold at a constant volume in catch basin 7 so long asflow rate A is equal to flow rate E plus the result of flow rate C times1 minus the ratio. Second, icing 68 will drain from catch basin 7 andhold at a constant volume in reservoir 17 so long as flow rate A isequal to flow rate C times 1 minus the ratio. Third, icing 68 will drainfrom catch basin 7 and increase in volume in reservoir 17 so long asflow rate A is less than flow rate C times 1 minus the ratio. Thissituation may result in overflowing reservoir 17 if the total volume oficing 68 not used to coat pastries 23 cannot be held in reservoir 17.Fourth, catch basin 7 and reservoir 17 will begin to slowly lose icing68 so long as flow rate A is greater than flow rate C times 1 minus theratio but less than flow rate E plus the result of flow rate C times 1minus the ratio. In this situation, the first vessel to be drained willdepend on the volume of icing 68 in each vessel, and can be calculatedaccording to the formulas recited above. Finally, icing 68 will drainfrom reservoir 17 and increase in volume in catch basin 7 so long asflow rate A is greater than flow rate E plus the product of flow rate Ctimes 1 minus the ratio. This situation may result in overflowing catchbasin 7 if the total volume of icing 68 not used to coat pastries 23cannot be held in catch basin 7.

In one embodiment, controller 202 is configured to adjust theindependent flow rates A, C, and E, and the ratio to run the systemaccording to one of the five options described above. In one embodiment,controller 202 runs a specific option manually selected by a user. Inanother embodiment, controller 202 selects the option based on signalsreceived from the system including the first and second thicknesssignals, the level signal, and/or the coating signal.

As can be appreciated, it is contemplated that the control schemesdiscussed above are examples of control arrangements configured toselectively source the icing 68 flowing into icing pan 70 from reservoir17 and catch basin 7 to improve the coating (e.g. icing or frosting)quality during the associated coating process. Accordingly, variouscombinations of controlling the pumps and valve, alone or incombination, may be utilize depending upon a particular coatingapplication, cost considerations, cost-effective availability ofrelevant signals (e.g. thickness, level signal, coating signal, moisturesignal, etc.), system speed, coated product quality requirements, etc.

It should be understood that the figures illustrate the exemplaryembodiments in detail, and it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects ofthe invention will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only. The construction and arrangements, shown in thevarious exemplary embodiments, are illustrative only. Although only afew embodiments have been described in detail in this disclosure, manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Someelements shown as integrally formed may be constructed of multiple partsor elements, the position of elements may be reversed or otherwisevaried, and the nature or number of discrete elements or positions maybe altered or varied. The order or sequence of any process, logicalalgorithm, or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may also be made in the design, operating conditions andarrangement of the various exemplary embodiments without departing fromthe scope of the present invention.

For purposes of this disclosure, the term “coupled” means the joining oftwo components directly or indirectly to one another. Such joining maybe stationary in nature or movable in nature. Such joining may beachieved with the two members and any additional intermediate membersbeing integrally formed as a single unitary body with one another orwith the two members or the two members and any additional member beingattached to one another. Such joining may be permanent in nature oralternatively may be removable or releasable in nature.

While the current application recites particular combinations offeatures in the claims appended hereto, various embodiments of theinvention relate to any combination of any of the features describedherein whether or not such combination is currently claimed, and anysuch combination of features may be claimed in this or futureapplications. Any of the features, elements, or components of any of theexemplary embodiments discussed above may be used alone or incombination with any of the features, elements, or components of any ofthe other embodiments discussed above. The embodiments of the presentinvention are discussed as being useable with icing such as water-basedicing. Depending upon the application, the icing may be a ready to useicing, an icing wherein all or a portion of the water is replaced with afat, or a water based icing where a both water and fat are present inthe icing. Additionally, this application uses the term icing, but itshould be understood that depending upon the viscosity and composition,icing may be referred to as frosting or visa versa.

In various exemplary embodiments, the relative dimensions, includingangles, lengths and radii, as shown in the Figures are to scale. Actualmeasurements of the Figures will disclose relative dimensions, anglesand proportions of the various exemplary embodiments. Various exemplaryembodiments extend to various ranges around the absolute and relativedimensions, angles and proportions that may be determined from theFigures. Various exemplary embodiments include any combination of one ormore relative dimensions or angles that may be determined from theFigures. Further, actual dimensions not expressly set out in thisdescription can be determined by using the ratios of dimensions measuredin the Figures in combination with the express dimensions set out inthis description.

What is claimed is:
 1. An icing coating system comprising: a temperatureregulated icing return hopper including walls defining a reservoir forcontaining an icing and a heat exchanger in thermal communication withthe reservoir wall; a belt for conveying a food product to be coatedwith icing, the belt including openings through which icing can flow; abelt sprocket assembly and a belt support arrangement for moveablysupporting the belt such that a top portion of the belt moves betweenthe belt sprocket assembly and the belt support arrangement in adirection and a bottom portion of the belt moves between the beltsprocket assembly and the belt support arrangement in a directionopposite to the top portion, the top portion of the belt including a topsurface and a bottom surface; a variable speed drive coupled to the beltsprocket assembly to move the belt at a selectable speed; a pan locatedbetween the top portion of the belt and the bottom portion of the belt;a variable-flow rate icing pump in fluid communication between thereservoir and the pan to pump icing from the reservoir to the pan; astructure which supports the belt sprocket assembly and the belt supportarrangement and the pan such that the pan is located between the top andbottom portions of the belt and the bottom surface of the top portion ofthe belt is further supported by the pan, wherein the flow rate of theicing pump is controlled to force icing into the pan through theopenings of the belt and above the top surface of a belt such that atleast a portion of food items located on the belt are resting within andcoated with icing; and a catch basin below the belt for receiving excessicing from the pan.
 2. The system of claim 1 wherein the hopper includesa fluid jacket through which a fluid at a predefined temperature flowsto regulate the temperature of the icing to reduce evaporation ofmoisture from the icing.
 3. The system of claim 2, wherein the fluid iswater, and the system includes a controller and temperature sensorassociated with icing in the system to maintain the temperature of theicing in the hopper between 120° and 130° degrees Fahrenheit.
 4. Thesystem of claim 3 including an in-feed conveyor which moves food itemsonto the belt and an out-feed conveyor for conveying food items coatedwith icing.
 5. The system of claim 2, further including a waterinduction system for controlling the moisture content of the icing, thewater induction system including a moisture sensor for sensing the watercontent of icing in the system, a controllable water injector for addingwater to icing in the system, and a controller coupled to the moisturesensor and the water injector to cause water to be added to icing tomaintain the icing within the moisture content required to maintainselected properties of icing flowing within the system.
 6. The system ofclaim 3, wherein the fluid flowing in the fluid jacket of the hopper isin the form of steam.
 7. The system of claim 3, wherein the fluidflowing in the fluid jacket of the hopper is in the form of mist.
 8. Thesystem of claim 1, wherein the belt is fabricated from stainless steelwire to form a mesh which defines the openings and is engaged with thebelt sprocket assembly.
 9. The system of claim 8, wherein the beltsupport arrangement includes stainless steel cylinders supported by thestructure substantially perpendicular to the direction of travel of thebelt.
 10. The system of claim 9, further comprising a roller assemblysupported above the top portion of the belt to force food items intoicing located above the top surface of the belt.
 11. A coating systemuseable for coating bakery such as donuts and cookies, the systemcomprising: a temperature regulated icing return hopper including wallsdefining a reservoir for containing the icing and a heat exchanger inthermal communication with the reservoir walls, wherein the hopperincludes a fluid jacket through which fluid at a predefined temperatureflows to regulate the temperature of the icing to reduce evaporation ofmoisture from the icing; a belt for conveying bakery to be coated withicing, the belt including openings through which icing can flow; a beltsprocket assembly and a belt support arrangement for moveably supportingthe belt such that a top portion of the belt moves between the beltsprocket assembly and the belt support arrangement in a direction and abottom portion of the belt moves between the belt sprocket assembly andthe belt support arrangement in a direction opposite to the top portion,the top portion of the belt including a top surface and a bottomsurface; a variable speed drive coupled to the belt sprocket assembly tomove the belt at a selectable speed; a pan located between the topportion of the belt and the bottom portion of the belt; a variable-flowrate icing pump in fluid communication between a catch basin and the panto pump icing from the reservoir to the pan; a structure which supportsthe belt sprocket assembly and the belt support arrangement and the pansuch that the pan is located between the top and bottom portions of thebelt and the bottom surface of the top portion of the belt is furthersupported by the pan, and a water induction system for controlling themoisture content of the icing, the water induction system including amoisture sensor for sensing the water content of icing in the system, acontrollable water injector for adding water to icing in the system, anda controller coupled to the moisture sensor and the water injector tocause water to be added to maintain icing within the moisture contentrequired to maintain selected properties of icing flowing within thesystem, wherein the flow rate of the icing pump is controlled to forceicing into the pan through the openings of the belt and above the topsurface of the belt such that at least a portion of the surfaces ofbakery located on the belt are resting within and coated with icing. 12.The system of claim 11 further comprising a fluid control system whichincludes a temperature sensor, variable flow fluid pump, controllableheat source and a controller coupled to the sensor pump and heat sourceto control the flow of the pump and the heat source based upon a signalgenerated by the temperature sensor representative of the temperature oficing in the system.
 13. The system of claim 12, wherein the belt isfabricated from stainless steel wire to form a mesh which defines theopenings and is engaged with the belt sprocket assembly.
 14. The systemof claim 13, wherein the belt support arrangement includes stainlesssteel cylinders supported by the structure substantially perpendicularto the direction of travel of the continuous belt.
 15. The system ofclaim 14, further comprising a roller assembly supported above the topportion of the belt to force food items into icing located above the topsurface of the belt.
 16. A method of preparing bakery such as donuts andcookies, the method comprising the steps of: containing icing in atemperature controlled vessel; sensing the temperature and moisture oficing contained within the vessel; heating the vessel and adding waterto the icing to maintain the temperature and moisture of the icingwithin a predetermined range; continuously moving icing from the vesselto a belt with a top surface which supports the bakery; and moving thebelt while the bakery is in contact with the belt and icing for apredetermined distance.
 17. The method of claim 16, further comprisingthe step of forcing the bakery into the icing at the top surface of thebelt.
 18. The method of claim 17, further comprising the steps ofconveying un-iced bakery to the belt and conveying iced bakery away fromthe belt.
 19. A combination comprising: a donut; a vessel of temperatureand moisture controlled water-based icing; a belt including a topsurface which supports the donut; a pump for pumping icing from thevessel through the belt onto the surface of the donut; and a supportstructure for movably supporting the belt relative to the vessel suchthat excess icing flows from the belt back into the vessel.
 20. Thecombination of claim 19, wherein the donut is toroidal shaped.
 21. Thecombination of claim 20, wherein the icing is chocolate flavored. 22.The combination of claim 19, wherein the donut is filled with a filling.23. A machine for simultaneously coating a plurality of items with acoating, each item having a first side and a second side, wherein theitems are placed on the machine in rows which are substantially straightand substantially perpendicular to the direction of travel of the itemsthrough the machine, the machine comprising: a first belt includingopenings through which the coating can flow; a first conveyor having afirst end and a second end, which moveably supports the first belt suchthat a top portion of the belt moves in a coating direction, the topportion transitions to a bottom portion of the belt at the second end,the top portion supporting and conveying a plurality of rows of aplurality of the items between the first and second ends in the coatingdirection wherein the items are supported on the first sides; a firstvariable speed drive coupled to the first conveyor to move the topportion in the coating direction; a pan located between the top andbottom portions of the first belt; a variable-flow rate icing pumpconfigured to pump the coating into the pan and through the openings tocoat the first side of the items with the coating as the items moveabove the pan; a second belt; a second conveyor which moveably supportsthe second belt such that a top portion of the second belt moves in thecoating direction; a second variable speed drive coupled to the secondconveyor to move the top portion of the second belt in the coatingdirection; a sensor which generates a signal in response to the passingof the plurality of rows of the plurality of items; a structure whichsupports the second conveyor relative to the first conveyor such thatcoated items drop from the first belt onto the top portion of the secondbelt such that the items are resting upon the second sides after beingdropped onto the second belt, the structure further supporting the senorrelative to the top portion of the first belt proximate to the secondend; a controller coupled to the variable speed drives and the sensor,the controller controlling the first variable speed drive to move thetop portion of the first belt at an average speed, and control thesecond variable speed drive to vary the speed of the second belt inresponse to the signal generated by the sensor, such that the secondbelt moves at a drop speed which is below the average speed of the firstbelt when the items are dropped onto the second belt.
 24. The machine ofclaim 23, wherein the drop speed is zero, and the second belt moves atan average speed which is the same as the average speed of the firstbelt.
 25. The machine of claim 24, further comprising a temperatureregulated coating return hopper including walls defining a reservoir forcontaining the coating and a heat exchanger in thermal communicationwith the reservoir wall, the hopper being in fluid communication withthe icing pump which pumps the coating from the hopper into the pan. 26.The machine of claim 25, further comprising a catch basin supportedbelow the first belt by the structure to receive excess coating from thepan.
 27. The machine of claim 26, wherein the items are donuts.
 28. Amethod for coating a plurality of items with a coating, each item havinga first side and a second side, comprising the steps of: placing theitems on a first belt including openings through which the coating canflow; moveably supporting the first belt such that a top portion of thebelt moves in a first direction, the top portion transitions to a bottomportion of the belt at an end and the bottom portion moves in a seconddirection opposite to the first direction, the top portion supportingand conveying a plurality of rows of a plurality of the items betweenthe first and second ends in the first direction wherein the cookeditems are supported on the first sides; controllably moving the topportion in the first direction at an average speed; pumping the coatinginto a pan located between the top and bottom portions of the first beltand through the openings to coat the first side of the items with thecoating as the items move above the pan; moveably supporting a secondbelt such that a top portion of the second belt moves in the firstdirection such that the items are dropped from the second end of thefirst belt onto the top portion of the second belt; sensing theplurality of rows of the plurality of items passing along the first beltat the end; and varying the speed of the second belt when the pluralityof rows of the plurality of items are sensed, such that the second beltmoves at a drop speed which is below the average speed of the topportion of the first belt when the items are dropped onto the secondbelt.
 29. The method of claim 28, wherein the drop speed is zero. 30.The method of claim 29, wherein the coating is heated.
 31. A coatingsystem for coating items with a liquid coating such as glaze, icing orfrosting, the system comprising: a return hopper defining a reservoirfor containing a coating; a belt for conveying an item to be coated withthe coating, the belt including openings through which the coating canflow; a belt sprocket assembly and a belt support arrangement formoveably supporting the belt such that a top portion of the belt movesbetween the belt sprocket assembly and the belt support arrangement in adirection and a bottom portion of the belt moves between the beltsprocket assembly and the belt support arrangement in a directionopposite to the top portion, the top portion of the belt including a topsurface and a bottom surface; a variable speed drive coupled to the beltsprocket assembly to move the belt at a selectable speed; a pan locatedbetween the top portion of the belt and the bottom portion of the belt;a first pump in fluid communication between the reservoir and the pan tomove the coating from the reservoir to the pan at a first controllableflow rate; a catch basin below the belt for receiving excess coatingfrom the pan; a proportional valve having an input port, a first outputport in fluid communication with the pan and a second output port influid communication with the return hopper, wherein the proportionalvalve is controllable to vary a ratio of the relative flow of thecoating from the first and second output ports; a second pump in fluidcommunication between the catch basin and the input port of theproportional valve to move the coating from the catch basin to the inputport at a second controllable flow rate, the second pump generating afirst thickness signal representative of the thickness of the coating;and a structure which supports the belt sprocket assembly and the beltsupport arrangement and the pan such that the pan is located between thetop and bottom portions of the belt and a bottom surface of the topportion of the belt is further supported by the pan, wherein thecontrollable flow rates of the first and second pumps and the ratio arecontrolled to selectively move the coating from the return hopper andthe catch basin into the pan based at least upon the thickness signal.32. The system of claim 31, further comprising a coating level sensorwhich generates a level signal representative of the level of thecoating within the catch basin and the flowrates of the pumps and theratio are further controlled based upon the level signal.
 33. The systemof claim 32, wherein the ratio may vary from between 1 to 0 where aratio of 1 represents that all of the flow into the input port isexiting the first output port and a ratio of 0 represents that all ofthe flow into the input port is exiting the second output port.
 34. Thesystem of claim 31, wherein the coating is moved from the return hopperand the catch basin into the pan and through the belt to a coating levelabove the top surface of the belt such that at least a portion of itemslocated on the belt are resting within, and coated with, the coating,the system further comprising a coating signal generator which generatesa coating signal related to the desired level of the coating, and theflowrates of the pumps and the ratio are further controlled based uponthe coating signal.
 35. The system of claim 33, wherein the first pumpgenerates a second thickness signal, and the flowrates of the pumps andthe ratio are further controlled based upon the second thickness signalsuch that the ratio is increased when the first thickness signal isgreater than the second thickness signal.
 36. A method for coatingcooked items with a coating such as glaze, icing or frosting, the methodcomprising: moving cooked items on a belt over a pan, the belt includingopenings through which the coating flows to a level above the belt andinto contact with the items; moving the coating from a return hopper tothe pan at a first flow rate; moving the coating from a catch basin tothe pan at a second flow rate and to the return hopper at a third flowrate, the catch basin being located below the pan to catch excesscoating; and controlling the first, second and third flow rates basedupon the thickness of the coating from the catch basin.
 37. The methodof claim 36 further controlling the first, second and third flow ratesbased upon the level of coating in the catch basin.
 38. The method ofclaim 36 further controlling the first, second and third flow ratesbased upon the level to which the coating flows above the belt.
 39. Themethod of claim 36, further controlling the first, second and third flowrates based upon the thickness of the coating from the return hopper.